SENR5574-04

January 1999

Engine Sensor Open or Short Circuit Test

Connect Electronic Service Tool to Cab Data Link
and check for ACTIVE Engine Sensor Open or
Short Circuit Code. If the code is not ACTIVE and
the Engine is not running properly, refer to
Troubleshooting Without A Diagnostic Code.
ACTIVE
Open or Short
Circuit Code

NOT
OK

Check Electrical Connectors and Wiring.

ACTIVE Open
Circuit Code

ACTIVE Short
Circuit Code
With the ignition key OFF, disconnect the
Sensor Connector with the ACTIVE Short
Circuit Code. Does the Short Circuit
Code remain Active?
Code Changes
To Open Circuit

Refer to PB-10

Short Circuit
Code Remains

If a Short Circuit code was Active before

the sensor was disconnected, but an
Open Circuit code became Active after the
sensor was disconnected then thoroughly
inspect the connector for moisture.
Inspect the seals and connect the sensor.
If the code reappears, the sensor or pigtail
harness is the problem. Temporarily
replace the sensor (connect sensor to
harness but do not install into engine) and
ensure the code is no longer Active. If the
code disappears with a new sensor,
replace the old sensor. STOP.

Measure the Sensor Supply Voltage with

a Voltmeter. Reading should be within
the range of 4.5 VDC to 5.5 VDC.

NOT
OK Refer
to
PC-34

OK
Install a short circuit between pin-C and
pin-B of the sensor harness connector
and check for an ACTIVE Short Circuit
Diagnostic Code. Does the Open
Circuit Code remain Active?
Open Circuit Code
Active with Jumper

Short Circuit Code

Active with Jumper

If a Short Circuit Code appears,

temporarily connect the suspect sensor.
If the Open Circuit code returns Active,
replace the sensor and verify the
diagnostic code does not return.

5EK1-UP
9CK1-UP
1YN1-UP
2PN1-UP
6TS1-UP

Disconnect the ECM Connector J2/P2 and check for Active

Diagnostic Codes. The Open Circuit Diagnostic Code
should be Active without the harness connected. Install a
jumper between the Sensor signal pin and pin-30 (Sensor
Common). A Short Circuit Code should be Active with the
jumper in place.
OK

Restart Test

NOT
OK

3176B, C-10, C-12, & 3406E

On-highway Engine
Electrical System

NOT
OK
If the Open Circuit Diagnostic Code is not active without
the harness connected, or the Short Circuit Diagnostic
Code does not appear with the short circuit in place,
temporarily install another ECM. Repeat this test step. If
the problem is resolved with the new ECM, verify the
problem returns with the old ECM. If the new ECM works
and the one on the engine did not, replace the ECM. STOP.

Install Sensor Bypass Wiring. Disconnect J2/P2

and remove the sensor signal wire from P2. Install
a 125-3662 3-Pin Engine Sensor Harness Bypass,
or make a bypass and route the bypass wire
directly from the ECM Connector P2 to the Sensor.

OK

Repair or
Replace Harness

Diagnostic Code Listing

Code
1-11
2-11
3-11
4-11
5-11
6-11
22-13
26-05
26-06
30-08
30-13
40-05
40-06
41-03
41-04
51-05
51-06
71-00
71-01
71-14
84-00
84-01
84-02
84-08
84-10
84-14
91-08
91-13
100-01
100-03
100-04
100-11
102-00
102-03
102-04
102-13
105-00
105-03
105-04
105-11
108-03
108-04
110-00
110-03
110-04
110-11
111-01
111-02
111-11
121-05
121-06
122-05
122-06
168-02
171-03
171-04
171-11
174-00
174-03
174-04
190-00
190-02
228-03
231-11
232-03
232-04
244-02
249-11
252-11
253-02
253-11
254-12

Description

Flash
Code

Troubleshooting
Guide Procedure

Cylinder 1 Fault
Cylinder 2 Fault
Cylinder 3 Fault
Cylinder 4 Fault
Cylinder 5 Fault
Cylinder 6 Fault
Check Timing Sensor Calibration
Multi-Function Output #1 Open Circuit
Multi-Function Output #1 Short Circuit
Invalid PTO Throttle Signal
PTO Throttle Sensor Calibration
Multi-Function Output #2 Open Circuit
Mulit-Function Output #2 Short Circuit
8 Volt Supply Above Normal
8 Volt Supply Below Normal
Multi-Function Output #3 Open Circuit
Multi-Function Output #3 Short Circuit
Idle Shutdown Override
Idle Shutdown Occurrence
PTO Shutdown Occurrence
Vehicle Overspeed Warning
Loss of Vehicle Speed Signal
Invalid Vehicle Speed Signal
Vehicle Speed Out of Range
Vehicle Speed Rate of Change
Quick Stop Occurrence
Invalid Throttle Signal
Throttle Sensor Calibration
Low Oil Pressure Warning
Oil Pressure Sensor Open Circuit
Oil Pressure Sensor Short Circuit
Very Low Oil Pressure
Boost Pressure Reading Stuck High
Boost Pressure Sensor Open Circuit
Boost Pressure Sensor Short Circuit
Boost Pressure Sensor Calibration
High Intake Manifold Temp Warning
Intake Manifold Temp Sensor Open Circuit
Intake Manifold Temp Sensor Short Circuit
Very High Intake Manifold Temp
Atmospheric Pr Sensor Open Circuit
Atmospheric Pr Sensor Short Circuit
High Coolant Temperature Warning
Coolant Temp Sensor Open Circuit
Coolant Temp Sensor Short Circuit
Very High Coolant Temperature
Low Coolant Level Warning
Coolant Level Sensor Fault
Very Low Coolant Level
Retarder Solenoid Lo/Hi Open Circuit
Retarder Solenoid Lo/Hi Short Circuit
Retarder Solenoid Med/Hi Open Circuit
Retarder Solenoid Med/Hi Short Circuit
Low or Intermittent Battery
Outside Air Temp Sensor Open Circuit
Outside Air Temp Sensor Short Circuit
No Ambient Air Temperature Data
High Fuel Temp Warning
Fuel Temp Sensor Open Circuit
Fuel Temp Sensor Short Circuit
Engine Overspeed Warning
Loss of Engine RPM Signal
A/C High Pressure Sw Open Circuit
J1939 Data Link Fault
5 Volt Supply Above Normal
5 Volt Supply Below Normal
Event Recorder Data Lost
J1922 Data Link Fault
Incorrect Engine Software
Check Customer or System Parameters
Check Transmission Customer Parameters
ECM Fault

72
72
73
73
74
74
42
69
69
29
29
66
66
21
21
67
67
01
47
47
41
31
36
36
36
00
32
28
46
24
24
46
25
25
25
42
64
38
38
64
26
26
61
27
27
61
62
12
62
14
14
14
14
51
00
00
00
65
13
13
35
34
19
58
21
21
02
58
59
56
56
53

PC-33
PC-33
PC-33
PC-33
PC-33
PC-33
PC-32
PB-25
PB-25
PB-12
PB-12
PB-25
PB-25
PB-12
PB-12
PB-25
PB-25
PB-21
PB-21
PB-21
PC-36
PB-14
PB-14
PB-14
PB-14
PB-36
PB-12
PB-12
PC-36
PC-35
PC-35
PC-36
PC-35
PC-35
PC-35
PC-37
PC-36
PC-35
PC-35
PC-36
PC-35
PC-35
PC-36
PC-35
PC-35
PC-36
PC-36
PB-17
PC-36
PB-20
PB-20
PB-20
PB-20
PB-11
PC-35
PC-35
PB-21
PC-36
PC-35
PC-35
PC-36
PC-31
PB-18
PB-24
PC-34
PC-34
PB-11
PB-24
PC-30
PC-30
PC-30
PC-30

1999 Caterpillar
All Rights Reserved

SENR5574-04
6 Page, JVD

Cooling Fan Always ON

Check the following on an Electronic Service Tool:
1. Cooling Fan Type Customer Parameter must be
programmed to "On-Off" or "Three Speed Fan".
If programmed to "None" the fan may always be ON.
2. For AUG96 and later Personality Modules,
Multi-Function Output #4 Customer Parameter
must be programmed to "Cooling Fan".
If both of the above are correctly programmed, inspect
ECM Connector J1/P1 for wire connected to pin-28. If no
wire is present at pin-28 then the ECM is not used to
control the Cooling Fan System. The problem is in the
OEM Vehicle System.
ECM is used to control the
Cooling Fan System

Turn ignition key ON, engine OFF. Access the Cooling

Fan Driver Special Test on an Electronic Service Tool.
Make the test Active and Not Active while listening for the
solenoid and/or relay to click as test status changes.
Is clicking detected?
NO
Refer to PB-18

YES

1.

2.

3.

Check A/C Fan status parameter on

Electronic Service Tool.
If A/C Fan status indicates "DISABLED" then the
ECM does not use and A/C High Pressure Switch to
control the Cooling Fan System.
If parameter indicates "OFF" at any time and the fan
is still ON then the A/C High Pressure circuit is not
the reason the Fan is ON.
If parameter indicates "ACTIVE DIAG", "ON", or
"COUNTING" the fan is ON because of the A/C High
Pressure circuit.
"OFF" at any time
or "DISABLED"

"ACTIVE DIAG",
"ON"Or "COUNTING"
Refer to PB-18

Check for logged or active diagnostic codes as follows:

1. 110-00 High Coolant Temp Warning
2. 110-03 Coolant Temp Sensor Open
3. 110-04 Coolant Temp Sensor Shorted
4. 110-11 Very High Coolant Temp
5. 105-00 High Manifold Temp Warning
6. 105-11 Very High Manifold Temp
For codes 110-03 and 110-04 refer to procedure
PC-35. For codes 105-00, 105-11, 110-00 and 110-11
refer to procedure PC-36.
No Listed Codes

The following conditions will turn Fan ON if engine

speed < 2250 rpm:
1. Engine not running.
2. During engine cranking.
3. Coolant sensor temp > 205F (96C).
4. Coolant temp sensor diagnostic active.
5. Intake manifold air temp > 189F (87C).
6. Intake manifold air temp > 162F (72C) with boost
pressure > 10 psi (70 kPa).
7. Retarder solenoid ON in high mode > 10 seconds.
8. A/C high pressure switch open or ECM counting.
9. A/C high pressure switch diagnostic active.
10. PTO On/Off switch in ON position.
If no listed condition exists then check for an open
circuit in the solenoid or ECM fan relay circuit. If
problem can not be found refer to procedure PB-18.

Printed in U.S.A.

3176B, C-10, C-12, & 3406E Engine Harness Wiring Diagram

P2 J2

CYL
NO.1

CYL
NO.2

CYL
NO.3

CYL
NO.4

CYL
NO.5

+V ENG SP/TMG
ENG SP/TMG COMMON
ENG SP/TMG

SPEED/TIMING
SENSOR

BOOST PRESS.
SENSOR COMMON
+5V

BOOST PRESSURE
SENSOR

ENGINE
RETR
SOL CYL
1&2

CYL
NO.6

ENGINE
RETR
SOL CYL
5&6

D789-WH
D790-OR
D791-YL
A706-GY
A705-BU
A704-GN
A703-BR
A702-PU
A701-GY
D786-BR
D787-GN
D788-BK

ENGINE
RETR
SOL CYL
3&4

OR
BK
WH
P9

A 996-GN
B 998-BR
C 999-WH
J9

1
2
J24 P24

GN
YL
OR
P3

C A746-PK
B 993-BR
A 997-OR
J3

GN C A747-GY
YL
B 993-BR
OR
A 997-OR
P22 J22

OIL PRESSURE
SENSOR

OIL PRESSURE
SENSOR COMMON
+5V

GN C 994-GY
YL B 993-BR
OR A 997-OR
P17 J17

WH C 995-BU
BK B 993-BR
OR A 997-OR
J10 P10

WH C C967-BU
BK B 993-BR
OR A 997-OR
J21 P21

FUEL TEMP
SENSOR

FUEL TEMP
SENSOR COMMON
+5V

WH C A751-YL
BK B 993-BR
OR A 997-OR
J23 P23

COOLANT TEMP
INTAKE MANF AIR TEMP
FUEL TEMP
SENSOR COMMON
+5V

OUTSIDE AIR TEMP

ECM GND STRAP

6
6

12

12

11

10

18

18

17

16

15

14

13

19

22

22

21

20

19

23

28

28

27

26

25

24

23

29

34

34

33

32

31

30

29

40

39

38

37

36

35

36

37

38

TO ECM
MOUNTING
BOLT

ECM

13

35

INTAKE MANF AIR TEMP

SENSOR COMMON
+5V

+V ENG SP/TMG
ENG SP/TMG COMMON
ENG SP/TMG
BOOST PRESSURE
ATM PRESSURE
OIL PRESSURE

VOLTAGE SUPPLY WIRES

COMMON WIRES
INPUT SIGNAL WIRES
OUTPUT SIGNALS WIRES

INTAKE MANF
AIR TEMP
SENSOR

INJECTOR COMMON 1 & 2

INJECTOR COMMON 3 & 4
INJECTOR COMMON 5 & 6
INJECTOR 6
INJECTOR 5
INJECTOR 4
INJECTOR 3
INJECTOR 2
INJECTOR 1
RETARDER SOLENOID MED/HI
RETARDER SOLENOID LO/HI
RETARDER SOLENOID COMMON
VEHICLE SPEED OUT+ (NOTE A)
TDC PROBE+/VEH SP IN+ (NOTE A)
TDC PROBE-/VEH SP IN- (NOTE A)
VEHICLE SPEED OUT - (NOTE A)

5
17
27
34
28
22
18
12
6
13
19
7
40
39
4
10
16
35
11
32
26
38
1
29
37
23
20
8
15
14
2
3
30
36
21
31
25
9
24
33

995-BU
C967-BU
A751-YL
993-BR
997-OR

ATM PRESSURE
SENSOR COMMON
+5V

COOLANT TEMP
SENSOR COMMON
+5V

D789-WH
D790-OR
D791-YL
A706-GY
A705-BU
A704-GN
A703-BR
A702-PU
A701-GY
D786-BR
D787-GN
D788-BK
D784-BU
D810-PU
D811-YL
D785-GN

996-GN
998-BR
999-WH
A746-PK
A747-GY
994-GY

ATM PRESSURE
SENSOR

COOLANT TEMP
SENSOR

J5 P5
12
10
8
6
5
4
3
2
1
11
9
7

39

40

Harness Side

Engine Harness
ECM Connector

ECM Side

Jack

Plug

3176B, C-10, C-12, & 3406E OEM Vehicle Harness Wiring Diagram
ECM CKT BKR

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

N/O
RELAY

+BAT.
-BAT.
ATA+
ATA-

C973-GN

SIGNAL-

SPEEDOMETER

C974-PU

SIGNAL+

SIGNAL+
SIGNAL-

TACHOMETER

PASSIVE
MAGNETIC
VEHICLE SPEED
SENSOR

450-YL

6
6

12

12

11

10

13

18

18

17

16

15

14

13

19

22

22

21

20

19

23

28

28

27

26

25

24

23

29

34

34

33

32

31

30

29

40

39

38

37

36

35

451-BR

D784-BU
D785-GN

BAT MTR
ALTERNATOR
GND

35

CRUISE ON/OFF

STARTER
MOTOR
(12V)

C993-BR

36

37

38

- 12V +

- 12V +

39

Harness Side

OEM Vehicle Harness

ECM Connector

C993-BR
(PEDAL RELEASED POSITION)

ECM

P1 J1
D799-GN
659-PK
C973-GN
C974-PU
450-YL
451-BR
D784-BU
D785-GN
C975-WH
C992-PU
C977-BU
C978-BR
C979-OR
E716-GY
E717-GN
B792-BU
B793-YL
C987-RD
E715-RD
D745-YL
E718-PK
E971-GN
A249-BK
K990-GN
K900-YL
C997-OR
C983-WH
C984-YL
E721-PK
E720-WH
C988-BK
E991-GY
C985-BU
C986-BR
C993-BR
K999-GN
K980-PK
K982-YL
L901-GY
K998-BU

C978-BR
C979-OR

C993-BR

LO
MED
HI
LO
MED
HI

ENGINE RETARDER
SOLENOID
ON/OFF SW

E716-GY

E717-GN

ENGINE RETARDER
SOLENOID SELECTOR SW

A/C HIGH PRESS. SW

N/C
E971-GN
TO J1939 DATA LINK CONNECTOR
TO J1939 DATA LINK CONNECTOR
TO J1939 DATA LINK CONNECTOR
+5V
COOL LEVEL NORMAL
COOL LEVEL LOW
SENSOR COMMON

COOLANT LEVEL SENSOR

C
D
A
B

C997-OR
C983-WH
C984-YL
C993-BR

TO J1922 DATA LINK CONNECTOR

TO J1922 DATA LINK CONNECTOR

C988-BK

ENG GND STUD

+8 V
THROTTLE POSITION
SENSOR COMMON

ENGINE
CYL HEAD

RD
WH
BK

Plug

C977-BU

SET/RESUME

C993-BR

Jack

CLUTCH N/C

ECM Side

- 12V +

BATTERY 3 BATTERY 2 BATTERY 1

40

C975-WH

SERVICE BRAKE N/C

C993-BR
C992-PU
(PEDAL RELEASED POSITION)

E715-RD

6 Page, Color 2, JVD

SENR5574-04

KEY SWITCH

659-PK

WARNING LAMP

C987-RD

VOLTAGE SUPPLY WIRES

COMMON WIRES
INPUT SIGNAL WIRES
OUTPUT SIGNALS WIRES

D799-GN

CHECK ENGINE LAMP

DASH DATA LINK

15

OFF C
ON
ST S

B793-YL
B792-BU

C
E
D
F
A
B

J11 P11
C985-BU
A
C986-BR
C
B
C993-BR

THROTTLE POSITION
SENSOR

22
27
10
16
17
11
18
12
20
14
24
25
15
19
13
1
7
6
4
28
40
38
26
39
33
36
2
23
9
3
5
34
35
37
29
8
32
31
30
21

CHECK ENGINE LAMP

WARNING LAMP
SPEEDOMETERECM GND STRAP
SPEEDOMETER+
TACHOMETER+
TACHOMETERVEHICLE SPEED IN+
VEHICLE SPEED INCRUISE CONT ON/OFF SW
SERVICE BRAKE SW
CLUTCH SW
SET
RESUME
RETARDER SOLENOID LO/HI SW
RETARDER SOLENOID MED/HI SW
ATA DATA LINK- (J1587)
ATA DATA LINK+ (J1587)
+BATTERY
UNSWITCHED +BATTERY
MULTI-FUNCTION OUTPUT #4 (NOTE B)
MULTI-FUNCTION OUTPUT #2
A/C HIGH PRESSURE SW
J1939 DATA LINK SHIELD (NOTE K)
J1939 DATA LINK- (NOTE K)
J1939 DATA LINK+ (NOTE K)
+5V
COOLANT LEVEL NORMAL
COOLANT LEVEL LOW
J1922 DATA LINK+
J1922 DATA LINK-BATTERY
MULTI-FUNCTION OUTPUT #3
+8V
THROTTLE POSITION
SENSOR COMMON
MULTI-FUNCTION INPUT #1
MULTI-FUNCTION INPUT #2
MULTI-FUNCTION INPUT #3
MULTI-FUNCTION SENSOR COMMON
MULTI-FUNCTION OUTPUT #1

OEM
INSTALLED

COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED

TO ECM
MOUNTING
BOLT

Does not crank,

refer to PA-18

Try to Start the Engine.

Engine Starts, but ECM does not

communicate with the Service Tool.

Connect Another Service Tool to the

ECM, but use the same Service Tool
Cables as in the previous step.

No Communications

Connect the Service Tool Using a

completely different set of Service Tool
Cables.

No Communications

Electronic Service Tool Will Not

Communicate with the ECM

OK

Repair
Service
Tool

OK

Repair
Cables

Disconnect ECM Connector P1 from

the ECM. Install a Caterpillar 129-2018
Harness Bypass. Connect the Bypass
directly to the Electronic Service Tool
Harness and ECM as shown below.

No Communications

Does
not start

ECM
ATA DATA LINK - (J1587)
ATA DATA LINK + (J1587)
+BATTERY
- BATTERY

12V

If ECM Serial Number ends in "CA",

ensure the Personality Module Chip is
completely snapped into the ECM
socket.

ECM and Service Tool

Communicate

NOT
OK

Refer
to PC-30

P1 J1
1
7
6
5

Harness Bypass Diagram

H
J
E
D
F
C
G
A
B

Dashed in Area is
Cable Shown Below

Either the vehicle wiring or another

device on the vehicle is causing
the communication problem.

ATA DATA LINKATA DATA LINK+

+BATTERY
- BATTERY

ATA DATA LINK +

Caterpillar Harness Bypass

Service Tool P/N 129-2018

- 12V +

Caterpillar
Service Tool "T"
Cable P/N 8T5275
or 139-4166 Cable

ATA DATA LINK -

- BATTERY

+ BATTERY

Engine Cranks, But Will Not Start

ECM Communicates

Connect Electronic Service Tool to Cab Data Link,

turn ignition key ON, engine OFF.
Attempt to access Truck Functions.

ECM does not communicate

Ensure after-market engine protection

devices (not installed by Caterpillar)
are not active, preventing the ECM
from receiving battery power.

OK

OK

If ECM Serial Number ends in "CA",

ensure the Personality Module Chip is
completely snapped into the ECM
socket.

OK

Ensure the Fuel Injector Connector (J5/P5)

is fully connected and free of corrosion.

OK

Observe engine rpm from Electronic

Service Tool while cranking the engine.

OK

Check ECM power and ground

NOT
OK connections with the ignition key switch
ON. Battery voltage at the ECM
Connector P1/J1 pin-6 +Battery to pin-5
-Battery should be 11.0 - 13.5 Volts DC.

Refer
to
PB-11

NOT
OK

Refer
to
PC-30

NOT
OK

Refer
to
PC-33

NOT
OK

Refer
to
PC-31

NOT
If the Personality Module has been
OK
recently replaced/updated, connect and
check for an active 252-11 Incorrect
Engine Software.

Refer
to
PC-30
OK

If the Truck is equipped with a CAT ID,

ensure Theft Deterrent is not Active.
Turn the ignition key ON, engine OFF,
the CAT ID will indicate Theft Deterrent
Active.

OK

Monitor the exhaust stack while

cranking - if no smoke is present there
may be a fuel supply or fuel quality
problem. Check fuel pressure, fuel
priming, and fuel filters.

OK

Check for combustion problems,

mechanical problems or extreme cold.